Method and apparatus for compressing and holding in compression woven fabric articles

ABSTRACT

The disclosure relates to a method and apparatus for compressing woven material or other compressible material, such as, but not limited to, a comforter set or bedding set. The bedding set or other woven material is placed into a reclosable storage bag which includes a reclosable zipper and a reclosable air valve. With the zipper open, the bag is compressed by a compression apparatus, typically in the absence of vacuum being applied, and, thereafter, the zipper is closed. Straps are wrapped around the compressed bag and the compressed bag is placed into a tote container or similar device. The result is a package with reduced volume, which reduces shipping and display costs, and is more aesthetically attractive to the consumer.

This application claims priority under 35 U.S.C. §119(e) of provisional patent application Ser. No. 61/304,734, filed on Feb. 15, 2010, the contents of which are incorporated by reference.

BACKGROUND OF THE DISCLOSURE

1. Field of the Disclosure

The present disclosure relates to a method and apparatus for producing compact shipping for woven fabric articles or compressible materials, such as, but not limited to, bedding materials.

2. Description of the Prior Art

In the prior art, it is well known to package woven fabric articles or compressible materials, such as bedding material, in a package or bag made from polymeric or similar material. However, the resulting packaging can be bulky which increases transportation, storage and display costs throughout the chain of commerce. Similarly, a consumer may be less prone to buy an unwieldy package.

The storage of polymeric bag within a box is disclosed in U.S. Pat. No. 7,588,160, entitled “Combined Storage Apparatus”, issued on Sep. 15, 2009 to Chen.

SUMMARY AND OBJECTS OF THE DISCLOSURE

It is therefore an object of the present disclosure to provide a method and apparatus for compressing woven fabric articles or compressible materials, such as, but not limited to, bedding materials, in order to provide a compact and aesthetically pleasing package.

This and other objects are attained by the present disclosure by providing a method and apparatus wherein compressible materials are placed into a plastic storage bag, typically of the type with an air valve and a reclosable zipper. The zipper remains open, and the compressible material and plastic storage bag are compressed, typically with a pneumatic or hydraulic apparatus. After the compression step has been performed, the zipper is closed thereby retaining the package in its compressed state. The plastic storage bag, with the compressed woven cloth material therein, is then placed into a reusable tote bag, typically including a clear vinyl portion. This results in an aesthetically pleasing container for display and sale to the customer. This further results in a tote bag and plastic storage bag which may be used by the consumer after the retail sale of the compressible material within the plastic storage bag and the tote bag.

BRIEF DESCRIPTION OF THE DRAWINGS

Further objects and advantages of the disclosure will become apparent from the following description and from the accompanying drawings, wherein:

FIG. 1 is a perspective view of a typical apparatus used for compressing the woven fabric articles.

FIG. 2 is a perspective view of the woven fabric article in the open plastic storage bag prior to compression.

FIG. 3 is a perspective view of the woven fabric article in the closed plastic storage bag after compression, with the zipper open.

FIG. 4 is a perspective view of the woven fabric article in the closed plastic storage bag after compression, with the zipper closed.

FIG. 5 is a perspective view of the closed storage bag, including the woven material, without the straps, inside the unzipped tote container.

FIG. 6 is a perspective view of the compressed woven fabric article in the closed storage bag, compared with a prior art package holding an uncompressed woven fabric article, illustrating the difference in thickness between the two.

FIG. 7 is an exploded view of the components of typical packaging of the final product.

FIG. 8 is a perspective view of a typical storage bag used in the present disclosure.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now to the drawings in detail wherein like numerals indicate like elements throughout the several views, one sees that FIG. 1 is a perspective view of pressing apparatus 10 of the present disclosure. Pressing apparatus 10 includes a frame 12, typically made from metal, which further includes a ground-engaging rectangular base 14, upright vertical elements 16 at the corners, and an upper horizontal portion 18. Tray 20 is positioned on rectangular base 14. Tray 20 typically includes an extended floor 21 which can serve as a feeding ramp. Tray 20 further typically includes first and second side elements 22, 24 which are inwardly and outwardly adjustable to accommodate different sizes of packages and may be configured as being movable. Tray 20 further typically includes rear element 25. Rear element 25 may be hinged to provide further access to package 100 (to be described) and to allow the package 100 to be pushed out of the rear of pressing apparatus 10. The use of first and second side elements 22, 24, along with rear element 25, allows the package 100 (to be described) to be compressed into a controlled shape, with the contents typically remaining very flat and smooth. Additionally, different shapes for the resulting product may be achieved by placing elements into different configurations.

Compression arm 30 reciprocates vertically toward and away from tray 20. Compression arm 30 includes flat compression plate 32 (typically sixteen by sixteen inches for applications involving bedding materials) which moves toward and away from tray 20 and impinge against the package 100 (to be described). The compression plate 32 provides a compression surface and is connected by first and second horizontal cross-beams 34, 36 which are, in turn, connected to respective first and second vertical guide rods 38, 40 which are engaged by respective first and second guide apertures 39, 41 and thereby constrained to vertical motion. Vertical drive rod 37 is connected between pneumatic drive 48 and compression plate 32. Pneumatic drive 48 thereby moves compression plate 32 vertically and applies a force to compression plate 32, thereby causing a compression force to be exerted across the area of compression plate. It has been found that a force of at least 2.5 to 3.5 pounds per square inch typically is required for sufficient compression of most compressible materials, such as, but not limited to, woven textile or cloth, particularly those frequently used for bedding materials.

FIGS. 2, 3 and 4 illustrate the steps of compressing the package 100. In FIG. 2, compressible material, such as, but not limited to, textile, cloth or woven material (typically, a comforter set or bedding set 102), is placed within a sealable storage bag 104 of the type shown in FIG. 8, and placed upon tray 20 of pressing apparatus 10, wherein the first and second side elements 22, 24 and rear element 25 of tray 20 have been adjusted in accordance with the desired dimensions of the final package 100. As shown FIG. 8, sealable storage bag 104 includes front and rear walls 106, 108, typically of transparent polymeric material, with an airtight or leak-resistant reclosable zipper 110 with first and second interlocking profiles 112, 114 which can be selectively opened (separated) or closed (interlocked) by movement of optional slider 115. Additionally, one of the front and rear walls 106, 108 includes a reclosable air valve 116 with an open position which allows air to pass freely therethrough and a closed position which provides an airtight or leak-resistant configuration.

After the comforter set 102 is placed in the sealable storage bag 104 as shown in FIG. 2, the reclosable zipper 110 is left at least partially open and the pneumatic drive 48 is activated thereby forcing compression plate 32 downwardly thereby compressing the package 100, including comforter set 102 within sealable storage bag 104 and driving, expelling or evacuating at least a portion of the air from the sealable storage bag 104 through reclosable zipper 110. It has been found that, typically, it is preferable to perform this operation at normal atmospheric pressure without any vacuum apparatus being applied to reclosable air valve 116 or any place else on the resealable storage bag 104 as such a vacuum operation typically deforms the comforter set 102, rendering it unsightly. In other words, a uni-directional compression is preferred over the spherical compression that would typically occur in the presence of a vacuum. Similarly, it has been found that applying vacuum to fur or to suede is particularly unsightly. After the pressing apparatus 10 has compressed the storage bag 104 and the contents thereof and driven air out through reclosable zipper 110 as shown in FIG. 3 (with the reclosable zipper 110 at least partially open), the reclosable zipper 110 is closed (as well as reclosable air valve 116, if not already closed) thereby rendering the storage bag 104 airtight or leak-resistant and maintaining the reduced size of storage bag 104 and the contents thereof, as shown in FIG. 4. An alternative aspect of the disclosure may close the zipper 110 prior to compression and expel the air through the reclosable air valve 116 during compression and then close the air valve 116 after compression. However, this aspect may not be preferred in some higher speed operations. The air valve 116 is typically provided in order to provide the consumer with a vacuum storage bag after purchase of the entire product of FIG. 7 in a retail establishment.

The storage bag 104 is then removed from the pressing apparatus 10 and placed into the forming section 200 of the packaging shown in FIG. 7. Alternatively, the pressing operation may be executed with the forming section 200 in place around the storage bag 104. Forming section 200 includes rigid or semi-rigid bottom panel 202 and two rigid or semi-rigid side panels 204, 206. Panels 202, 204, 206 are sized for flush insertion into tote container or bag 300. Strap portions 208, 210 extend from bottom panel 202 and terminate in respective snap buckle portions 212, 214. Snap buckle portions 212, 214 can inter-engage in a conventional manner to form first strap 216. Likewise, strap portions 218, 220 extend from bottom panel 202 and terminate in respective snap buckle portions 222, 224. Snap buckle portions 222, 224 can inter-engage in a conventional manner to form second strap 226.

Strap portions 208, 210, 218, 220 are engaged tightly around storage bag 104 and snap buckle portions 212, 214 and 222, 224 are inter-engaged to each other to form first and second straps 216, 226 which are tightly wrapped around storage bag 104, thereby constraining storage bag 104 and maintaining the size and shape of storage bag 104.

The storage bag 104, with forming section 200 engaged thereto, is then placed within cloth tote container or bag 300, which serves as an outer container typically formed as a luggage-type container, thereby further constraining storage bag 104. Tote container or bag 300 includes a bottom wall 302 with a square or rectangular shape and four side walls 304, 306, 308, 310 extending therefrom. Top wall 312 extends from side wall 304 and includes cloth zipper 315 around three sides thereof for releasable attachment with side walls 306, 308 and 310. The terms “top”, “bottom” and “side” are arbitrary in this context as the orientation of tote container or bag 300 can be easily changed. Further, top wall 312 typically includes transparent window or portion 313 so as to allow the purchaser to see the contents of storage bag 104. Side wall 308 includes handle 314 sewn or otherwise attached thereto, thereby allowing a customer to carry the tote container or bag 300, with the storage bag 104 and comforter set 102 therein.

After the storage bag 104 and comforter set 102 have been placed into the tote container or bag 300, an optional fabric sample 400 (matching in appearance to the comforter set 102) may be placed over the storage bag 104, including the comforter set 102, and the zipper 315 of tote container or bag 300 closed, so that the display through transparent top wall 102 is more aesthetically pleasing.

In this way, an appealing and compact package for the comforter set 102 (or similar woven or similar material objects) is achieved as shown in FIG. 6. This results in a vacuum storage bag being sold in a retail establishment with the compressed product within the vacuum storage bag, so that the product may be removed and the vacuum storage bag and tote bag reused by the consumer. Moreover, a comparison between the size of the tote container 300 resulting from the present embodiment and the size of conventional packaging 500 of bedding materials is shown in FIG. 6. A typical size of prior art packaging for a queen size set is 21 inches by 16 inches by 12 inches, while the present embodiment may achieve a size of 21 inches by 16 inches by 6 inches, or a reduction in volume of fifty percent.

Thus the several aforementioned objects and advantages are most effectively attained. Although preferred embodiments of the invention have been disclosed and described in detail herein, it should be understood that this invention is in no sense limited thereby and its scope is to be determined by that of the appended claims. 

1. A method, including the steps of: providing a package including a reclosable zipper; placing compressible material within the package; compressing the package thereby expelling a portion of air from the package; after the compressing step, rendering the package leak resistant; and after the rendering step, constraining the package.
 2. The method of claim 1 wherein the compressible material includes woven material.
 3. The method of claim 1 wherein the compressible material includes textile or cloth.
 4. The method of claim 2 wherein the step of expelling air from the package is performed with the reclosable zipper in an at least partially open configuration and the step of rendering the package leak resistant is performed by closing the reclosable zipper.
 5. The method of claim 4 wherein the step of compressing the package is performed in the absence of a vacuum being applied to the package.
 6. The method of claim 5 wherein the step of compressing is performed with at least 2.5 pounds per square inch of force applied to the package.
 7. The method of claim 5 wherein the step of compressing is performed with at least 3.5 pounds per square inch of force applied to the package.
 8. The method of claim 6 wherein the package further includes an air valve with an open position and a closed position.
 9. The method of claim 8 wherein the reclosable zipper includes two interlocking profiles which, when interlocked, form a leak-resistant seal.
 10. The method of claim 9 wherein the reclosable zipper includes a slider.
 11. The method of claim 5 wherein the step of constraining the package includes wrapping straps around the package.
 12. The method of claim 11 further including the step of providing a forming section around the package during the step of compressing, wherein the wrapping straps extend from the forming section.
 13. The method of claim 12 wherein the forming section includes rigid or semi-rigid bottom panel.
 14. The method of claim 13 wherein the forming section further includes first and second rigid or semi-rigid side panels extending from the bottom panel.
 15. The method of claim 14 wherein the step of constraining the package further includes the step of placing the package into an outer container after the step of wrapping straps around the package.
 16. The method of claim 15 wherein the outer container is a luggage-type container.
 17. The method of claim 15 wherein the outer container is a tote container.
 18. The method of claim 17 wherein the tote container includes a rectangular or square bottom wall with four side walls extending therefrom, and a top wall extending from one of the side walls.
 19. The method of claim 18 wherein the tote container includes a cloth zipper formed around three sides of the top wall for attaching to three of the side walls.
 20. The method of claim 19 wherein the top wall includes a transparent panel.
 21. The method of claim 20 wherein one of the side walls of the tote container includes a handle attached thereto.
 22. The method of claim 21 further including placing a sheet of material between the package and the transparent panel of the top wall of the tote container, whereby the sheet of material is visible through the transparent panel.
 23. The method of claim 22 wherein the sheet of material has an appearance which matches that of the compressible material.
 24. A method, including the steps of: providing a package including front and rear walls, a mouth with a reclosable zipper; and an air valve with an open position and a closed position; placing compressible material within the package with the reclosable zipper at least partially open; compressing the package thereby expelling a portion of air from the package through the reclosable zipper, wherein the step of compressing is performed by a compressing device with a tray for receiving the package and a drive shaft including a compression surface thereon; after the compressing step, rendering the package leak-resistant; and after the step of rendering the package leak-resistant, constraining the package.
 25. The method of claim 24 wherein the compressible material includes woven material.
 26. The method of claim 24 wherein the compressible material includes textile or cloth.
 27. The method of claim 25 wherein the step of compressing is performed by a pneumatic drive.
 28. The method of claim 27 wherein the step of compressing is performed in the absence of a vacuum applied to the package.
 29. The method of claim 28 wherein the step of compressing is performed with at least 2.5 pounds per square inch of force applied to the package.
 30. The method of claim 28 wherein the step of compressing is performed with at least 3.5 pounds per square inch of force applied to the package.
 31. The method of claim 30 wherein the step of compressing is performed with the zipper open and the step of rendering the package leak-resistant is performed by closing the zipper.
 32. The method of claim 31 wherein the reclosable zipper includes two interlocking profiles which, when interlocked, form a leak-resistant seal.
 33. The method of claim 32 wherein the reclosable zipper includes a slider.
 34. The method of claim 32 wherein the step of constraining the package includes wrapping straps around the package.
 35. The method of claim 34 further including the step of providing a forming section around the package during the step of compressing, wherein the wrapping straps extend from the forming section.
 36. The method of claim 35 wherein the forming section includes rigid or semi-rigid bottom panel.
 37. The method of claim 36 wherein the forming section further includes first and second rigid or semi-rigid side panels extending from the bottom panel.
 38. The method of claim 37 wherein the step of constraining the package further includes the step of placing the package into an outer container after the step of wrapping straps around the package.
 39. The method of claim 38 wherein the outer container is a luggage-type container.
 40. The method of claim 38 wherein the outer container is a tote container.
 41. The method of claim 40 wherein the tote container includes a rectangular or square bottom wall with four side walls extending therefrom, and a top wall extending from one of the side walls.
 42. The method of claim 41 wherein the tote container includes a cloth zipper formed around three sides of the top wall for attaching to three of the side walls.
 43. The method of claim 42 wherein the top wall includes a transparent panel.
 44. The method of claim 43 wherein one of the side walls of the tote container includes a handle attached thereto.
 45. The method of claim 44 further including placing a sheet of material between the package and the transparent panel of the top wall of the tote container, whereby the sheet of material is visible through the transparent panel.
 46. The method of claim 45 wherein the sheet of material has an appearance which matches that of the compressible material. 47-61. (canceled)
 62. The method of claim 1 wherein the step of compressing is performed with the package in a tray, the tray including side elements configured to determine a shape of the package after the step of compressing.
 63. The method of claim 62 wherein the tray further includes a rear element configured to determine a shape of the package after the step of compressing.
 64. The method of claim 24 wherein the tray includes side elements configured to determine a shape of the package after the step of compressing.
 65. The method of claim 64 wherein the tray further includes a rear element configured to determine a shape of the package after the step of compressing. 